Patient contacting seal and mask using same

ABSTRACT

A seal and a respiraoty mask having a seal adapted for confronting engagement with a surface of a user to form an interface therewith. The seal includes a first portion defined by a gel substance. In one embodiment, the seal includes a selectively formable substance adapted to be molded from a first pattern into a second pattern and to retain the second pattern responsive to being so molded. The seal and mask having the seal in this embodiment is tailored to patient by causing the formable portion of the seal to be placed in a malleable state, applying the seal to the patient while the formable portion is in the malleable state, and causing the formable portion to be placed in a fixed state to retain a shape generally conforming to the portion of the patient underlying the seal.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation application under 35 U.S.C. §120 ofU.S. patent application Ser. No. 11/051,854, filed Feb. 4, 2005, whichis a Continuation application under 35 U.S.C. §120 of U.S. patentapplication Ser. No. 10/106,658, filed Mar. 26, 2002, now U.S. Pat. No.6,895,965, which is a Divisional application under 35 U.S.C. §120/121 ofU.S. patent application Ser. No. 09/388,326, filed Sep. 1, 1999, nowU.S. Pat. No. 6,397,847, which claims priority under 35 U.S.C. §119(e)from Provisional U.S. Patent Application No. 60/103,091 filed Oct. 5,1998, and which is also a Continuation-in-Part under 35 U.S.C. §120 ofU.S. patent application Ser. No. 08/832,267 filed Apr. 3, 1997, now U.S.Pat. No. 5,884,624, which is a Continuation under 35 U.S.C. §120 of U.S.patent application Ser. No. 08/525,404 filed Sep. 9, 1995, now U.S. Pat.No. 5,647,357.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention pertains to a customizable seal that contacts aportion of a patient to provide a comfortable and customizable interfacebetween an external device, such as a respiratory mask, and the patient.The present invention also pertains to a respiratory mask having such acustomizable seal and to a method of interfacing a patient with anexternal device, such as a respiratory mask, using such a seal.

2. Description of the Related Art

A variety of respiratory masks are known having a flexible seal thatcovers the areas surrounding the nose and/or mouth of a human user andthat are designed to create a continuous seal against the user's face.Because of the sealing effect created, gases can be provided at apositive pressure within the mask for consumption by the user. The usesfor such masks range from high altitude breathing (aviationapplications), swimming, mining and fire fighting applications andvarious medical diagnostic and therapeutic applications.

One requisite of many of these masks, particularly medical respiratorymasks is that they provide an effective seal against the user's face toprevent leakage of the gas being supplied. Commonly, in conventionalmask configurations, a good mask-to-face seal has been attained in manyinstances only with considerable discomfort for the user. This problemis most crucial in those applications, especially medical applications,which require the user to wear the mask continuously for hours orperhaps even days. In such situations, the user will not tolerate themask for long durations and optimum therapeutic or diagnostic objectiveswill not be achieved, or will be achieved with great difficulty andconsiderable user discomfort.

Several types of respiratory masks for the types of applicationsmentioned above are known. Perhaps the most common type of maskincorporates a smooth sealing surface extending around the periphery ofthe mask and exhibiting a generally uniform, i.e., predetermined orfixed, seal surface contour that is intended to be effective to sealagainst the user's face when force is applied to the mask with thesealing surface in confronting engagement with the user's face. Thesealing surface typically consists of an air or fluid filled cushion, orit may simply be a molded or formed surface of a resilient seal elementmade of an elastomer such as plastic, rubber, silicone, vinyl or foam.

Such masks have performed well when the fit is good between the contoursof the seal surface and the corresponding contours of the user's face.This may occur, for example, if the contours of the user's face happento match well with the predetermined contours of the seal. However, ifthe seal fit is not good, there will be gaps in the seal-to-faceinterface resulting in gas leaking from the mask at the gaps. Excessiveforce will be required to compress the seal member to close the gaps andattain a satisfactory seal in those areas where the gaps occur. Suchexcessive force is unacceptable because it produces high pressure pointselsewhere on the face of the user where the mask seal contour isforcibly deformed against the face to conform to the user's facialcontours. This will produce considerable user discomfort and possibleskin irritation and breakdown anywhere the applied force exceeds thelocal perfusion pressure, which is the pressure that is sufficient tocut off surface blood flow. Ideally, contact forces should be limitedbetween the mask and the user's face to avoid exceeding the localperfusion pressure, even at points where the mask seal must deformconsiderably.

The problem of seal contact force exceeding desirable limits is evenmore pronounced when the positive pressure of the gas being supplied isrelatively high or is cyclical to relatively high levels. Because themask seals by virtue of confronting contact between the mask seal andthe user's face, the mask must be held against the face with a forcesufficient to seal against leakage of the peak pressure of the suppliedgas. Thus, for conventional masks, when the supply pressure is high,headstraps or other mask restraints must be relatively tightly fastened.This produces high localized pressure on the face, not only in the zoneof the mask seal, but at various locations along the extent of theretention straps as well. This, too, will result in discomfort for theuser after only a brief time. Even in the absence of excessive localizedpressure points, the tight mask and headstraps may become extremelyuncomfortable, and user discomfort may well cause discontinuedcooperation with the treatment regimen. Examples of respiratory maskspossessing continuous cushion sealing characteristics of the type justdescribed are provided in U.S. Pat. Nos. 2,254,854 and 2,931,356.

U.S. Pat. No. 5,181,506 describes a protective gas mask for militaryapplications. The mask includes a three-layer face piece, the centrallayer of which is a thick layer of relatively stiff material havingpreformed V-shaped channels. The channels are “overfilled” with a gel orboth gel and compressed air to create bulges in an inner face-contactinglayer that are adapted to seal against the contours of a user's face.The inherent stiffness of the central layer in combination with thestructural rigidity provided by the V-shaped channels, especially whenoverfilled with gel/air, results in a comparatively unyielding facialseal. Indeed, the mask is deployed in combination with a tightly fittinghood in order to draw the face piece firmly against the user's head togenerate the desired facial seal. As will be appreciated, the comfortafforded such a construction is quite limited and certainly notappropriate for those applications, such as respiratory therapysituations, where a user must occasionally wear a mask for prolongedperiods of time.

Several classes of cushion materials, including gels and foams, wereanalyzed in a study by S. F. C. Stewart, V. Palmieri and G. V. B.Cochran, Arch. Phys. Med. Rehabil., Vol. 61, (May 1980). That studycompared the relative advantages and disadvantages of such cushionmaterials when used as wheelchair cushions, specifically the effects ofsuch materials on skin temperature, heat flux and relative humidity atthe skin-cushion interface. Each of these factors, along with appliedpressure in excess of local perfusion pressure, has been identified as acontributor to breakdown of skin tissue at the skin-cushion interface.

In that study, foam cushions were reported to increase skin temperaturesby several degrees after a few hours of use. This was suggested to be aresult of the comparatively low heat flux characteristics of foammaterials. That is, the foam materials and the air entrapped within themtend to be poor conductors of heat. Conversely, gel pads, as a group,showed a considerably higher heat flux than foam, sufficient, in fact,to maintain skin temperatures relatively constant after several hours ofuse. The sole benefit of foam versus gel reported in the study was thatfoams produced lesser relative humidity than gels at the skin-cushioninterface. This was attributed to the open cell structure of the foamswhich provide a pathway through which moisture can diffuse. This seemingadvantage is somewhat problematic, however, in that open cell foam tendsto promote bacteria growth when exposed to perspiration. Bacteria, inturn, contaminates the foam thereby considerably hindering its usefulservice life.

These and other detrimental characteristics have been observed as wellin the foam-type respiratory mask seals discussed above. Hence, apartfrom generally failing to provide optimum sealing with respect to auser's face, the inherent qualities of foam mask seals have been linkedto skin irritation and breakdown, particularly at some of the moreprominent facial contours, such as the cheek bones and bridge of thenose.

Moreover, whether air, fluid or, in the case of U.S. Pat. No. 5,181,506,gel filled, or whether formed as an elastomer such as foam, plastic,rubber, silicone and the like, the resiliency or recoil characteristicsof presently available cushion type respiratory mask seals have not beenwell suited to form an effective seal with the topography of the user'sface in the absence of considerable headstrap tensile forces.

One method to reduce the existence of gaps at the mask-to-face interfaceis to customize the seal so that it conforms to the fine contours of thepatient's face. This can be thought of as a micro-customization of theseal because the goal of the customization is to match the seal to thespecific external features of the user's face, i.e., the contourscreated by the soft tissue of the patient. For example, if the user hasan unusually deep crease in his or her face, a micro-customized mask hasa user interface surface that matches this deep crease, therebypreventing a gap from existing at the crease. In short, amicro-customized seal is tailored to conform to the contours of the softsurface tissue of the patient.

Various techniques have been proposed for micro-customizing a seal, suchas the seal on a face mask. It is known, for example, to provide amicro-customized seal by making an impression or cast of the patient'sface. The cast is then used as a form to produce a fully customized maskspecifically tailored to match that patient's face. This technique,however, is time consuming and costly, and, therefore, is not wellsuited for conventional, large-scale manufacturing processes.

The present inventor also discovered that, contrary to expected results,a satisfactory seal may not result from a micro-customized mask. It isbelieved that a relatively detailed micro-customized mask, closelymatching the detailed contours of the soft tissue at the surface of apatient, does not provide a satisfactory seal because changes in sealposition and/or changes in the soft tissue of the patient may result innew gaps being created between the seal and the patient. For thisreason, a mask that has a micro-customized seal made from theabove-described casting process, because it is specifically designed tomatch the contours in the soft tissue of the patient's face at the timethe cast was made, typically does not have the ability, or has only alimited ability, to change its shape in the event of changes in thepatient's shape or shifts in the mask position. This disadvantage isespecially pronounced if the mask having such a micro-customized seal isused in situations where the patient is likely to move and/or insituations where the mask is likely to be jostled, such as during sleep.

It is also known to contour the patient-contacting surface of the maskto match the general facial contours of the patient. This can be thoughtof as a macro-customization because the goal of customization is not tomatch the seal to the detailed external features of the user defined bythe external soft tissues, but to match the seal to the general shape ofthe user, such as the underlying bone structure. Macro-customizationprovides an advantage over micro-customization in that there is less ofa chance that changes in the patient's soft tissue or slight shifts inthe seal will result in gaps being created. Also, a macro-customizedseal provides a more effective seal than a micro-customized seal insituations where there may be differences between the contours of theunderlying bone structure and the overlying soft tissue. For example, ifthere is a protruding bone that is not apparent because the protrusionis masked by soft tissue, a macro-customized seal will conform to theprotruding bone structure, thereby minimizing the chances of leaksexisting at a site near the protruding bone.

One technique for providing a macro-customized seal on a respiratorymask is to provide a variety of different masks having a variety ofdifferently shaped seals. The user would use the mask having the sealthat most closely matches the facial structure of that user. Forexample, several masks having different sized nose bridge arches can bemade available to the user, with the user selecting the mask having thenose bridge arch size that most closely matches his or her nose. Thistype of mask provides some degree of customization, as opposed, forexample, to a flat surface, for the mask-to-patient interface. However,because this macro-customized, i.e., off the shelf, mask is notspecifically customized to match the facial features of a specific user,it often does not permit a sufficient degree of customization to accountfor facial contours specific to each patient. For example, for patientswith unusual facial features, off the shelf macro-customized maskstypically do not provide a satisfactory seal and can result in pressurepoints being created as the patient attempts to close these gaps withincreased strapping force.

Macro-customization of a respiratory mask facial seal can also beaccomplished by measuring the general facial features of the patient andproducing a seal that matches these general features. Thismacro-customization process, however, suffers from the samedisadvantages discussed above with respect to the micro-customizationprocess. Namely, it is time consuming, uneconomical and inefficient toattempt to mass produce such specifically tailored macro-customizedmasks.

Macro-customization also suffers from a disadvantage in that leaksresulting from the physical characteristics of the soft tissue of thepatient are not minimized. For example, if there is a deep crease in thesoft tissue, a macro-customized seal is generally not as prone toreducing leaks at the crease as a micro-customized seal. Instead, theuser will typically attempt to minimize such leaks by increasing thestrapping force, thereby creating the problems of high localizedpressure on the surface of the patient.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide acustomizable seal adapted for confronting engagement with a surface of auser to form a sealed interface therewith that overcomes theshortcomings of conventional seal techniques. This object is achieved,according to one embodiment of the present invention, by providing aseal having a first portion defined by a pliable gel substance thatrecoils back to substantially its original shape when not stressed andthat has a resiliency defined as a Shore 00 durometer of less than about10. The seal includes a first portion adapted to contact a face of ahuman user. In a further embodiment, the seal is also formed from aselectively formable substance that is adapted to be molded from a firstpattern into a second pattern and to retain the second patternresponsive to being so molded. The first portion of the seal has theeffect of providing a micro-customization of the seal in that the sealreadily conforms to match the external contours of the user, such asthose features defined in a patient's soft tissues. The second portionof the seal has the effect of providing a macro-customization in that itcan be molded to match the general features, such as the underlying bonestructure, of the patient.

The present inventor discovered that headstrap tensile forces and,therefore, the compressive forces exerted by the mask against a user'sface, can be reduced substantially with respect to existing cushion-typerespiratory masks when the first portion of the seal in a respiratoryfacial mask is fabricated from materials, such as a gel substance,having recoil characteristics analogous to that of human fat. The firstportion of the seal behaves much like natural biological tissue andtends to conform naturally to the detailed contours of the user's faceunder the influence of very low headstrap forces. Therefore, the firstportion of the seal provides the advantages associated withmicro-customization in that the seal can conform to the detailedfeatures of the user's skin.

The present inventor also discovered that, in addition to their otheraforementioned advantages, gel substances can be produced that simulatethe recoil properties of human fat tissue. In one embodiment, the gelsubstance is, for example, a viscoelastic polyurethane polymerpossessing a resiliency characteristic corresponding to that of humanfat tissue yet having a recoil property such that the seal returns backto substantially its original shape after being stressed. In a furtherembodiment, a protective covering is provided over an exterior surfaceof the gel substance. In the absence of such a covering, the inherenttacky quality of the gel substance serves to enhance adhesion of thefacial seal to the user's skin. Alternatively, if tackiness is notdesired, the surface of the annular member may be covered with a coatingof powdered talc, silicone or similar biocompatible material. Mostpreferably, however, an exposed portion of the gel substance isencapsulated in a thin, pliable, membranous covering to enhance thedurability and washability of the facial seal.

Because the portion of the facial seal that contacts the user simulatesthe recoil characteristics of human fat tissue, the user experiences thesensation of a natural substance against his or her skin when anexternal device, such as a mask, having such a seal is donned.Furthermore, because the seal includes a second portion that can bemolded from a first pattern into a second pattern and, thereafter,retains the second pattern, a respiratory mask having such a seal can becustomized to match the general facial characteristics of the user. Thesecond portion of the seal provides the advantages associated withmacro-customization in that the seal conforms to the general features ofthe user. Consequently, an external device, such as a mask, providedwith such a customizable seal can be comfortably urged into continuoussealing engagement with a user's face with less headstrap tension thanother masks heretofore known in the art. Furthermore, the fat-likequalities of the gel substance in the first portion of the seal allowthe gel to effectively fill gaps on the surface of the user and mold toother facial contours, thereby minimizing leakage of pressurized gassupplied to the mask. The gel substance also serves to efficientlydissipate heat while resisting the bacteria growth associated with foamtype mask seals.

It is a further object of the present invention to provide a respiratorymask using a customizable seal described above. This object is achievedby providing a respiratory mask that includes a relatively rigid maskbody having a first opening and a second opening defined therein. A sealis operatively connected to the mask body and adapted for confrontingengagement with a surface of a user to form a sealed interfacetherewith. As discussed above, the seal includes a first portion definedby a gel substance and a second portion associated with the firstportion that includes a selectively formable substance adapted to bemolded from a first pattern into a second pattern and to retain thesecond pattern responsive to being so molded.

It is yet another object of the present invention to provide a method ofinterfacing a patient with an external device using the customizableseal described above. This object is achieved by providing a method thatincludes the steps of: (1) providing an external device having a sealadapted for confronting engagement with a surface of the patient to forma sealed interface therewith, the seal including a selectively formableportion having a malleable state and a fixed state, (2) causing theformable portion of the seal to be placed in the malleable state, (3)applying the seal to the surface of the patient while the formableportion is in the malleable state so that the formable portion takes ona shape generally conforming to the contour of a portion of the patientunderlying the seal, and (4) causing the formable portion to be placedin the fixed state to retain the shape generally conforming to thecontour of the portion of the patient underlying the seal.

These and other objects, features and characteristics of the presentinvention, as well as the methods of operation and functions of therelated elements of structure and the combination of parts and economiesof manufacture, will become more apparent upon consideration of thefollowing description and the appended claims with reference to theaccompanying drawings, all of which form a part of this specification,wherein like reference numerals designate corresponding parts in thevarious figures. It is to be expressly understood, however, that thedrawings are for the purpose of illustration and description only andare not intended as a definition of the limits of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevation view of a respiratory mask including a firstembodiment of a seal according to the present invention;

FIG. 2 is a side elevation view of the respiratory mask of FIG. 1 inconfronting, sealing engagement with a user's face, the respiratory maskbeing schematically depicted in communication with a source ofrespiratory gas;

FIG. 3 is a cross-sectional view of the respiratory mask taken alongline III-III of FIG. 1;

FIG. 4 is a cross-sectional view of the respiratory mask taken alongline IV-IV of FIG. 2;

FIG. 5 is an elevational cross-sectional view of a respiratory masksimilar to the view illustrated in FIG. 3 illustrating a seal accordingto another embodiment of the present invention;

FIG. 6 is a cross-sectional view of a respiratory mask similar to theview illustrated in FIG. 3 illustrating a seal according to a stillfurther embodiment of the present invention;

FIGS. 7 and 8 are cross-sectional views of a seal according to otherembodiments of the present invention;

FIG. 9 is an exploded view of a respiratory mask and seal according to afurther embodiment of the present invention;

FIG. 10 is a cross-sectional view of a respiratory mask similar to theview illustrated in FIG. 3 illustrating a retaining member used incustomizing the seal to the patient in a further embodiment of thepresent invention; and

FIG. 11 is a front elevation view of the respiratory mask and retainingmember shown in FIG. 9.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1-4, there is generally indicated at 10, arespiratory mask including a shell or body 12 having an open side 14that defines a generally annular surface 16 to which is sealinglyaffixed a seal 18 constructed according to a first embodiment of theinstant invention. Mask body 12 is preferably, although not necessarily,a generally rigid shell, whereas facial seal 18, in the illustratedembodiment, is a flexible, resilient unitary member that will bedescribed in greater detail hereinafter.

Mask body 12 also defines an opening 20 to which, in the illustratedembodiment, there is attached a fluid coupling device, such as a swivelcoupling 21 for carrying fluid, such as a breathing gas, between thechamber within the mask and the external gas source. It is to beunderstood that the present invention contemplates a variety of fluidcoupling devices be attachable, either permanently or selectively, toopening 20 to carry fluid to or from the chamber defined by mask 10. Inthe illustrated embodiment, opening 20 and intervening coupling 21connect mask 10 via a conduit, which is represented by dashed line 22,to a source of gas 24, e.g., a blower or other suitable device, forproviding a flow of pressurized breathing gas, for example, foradministration of the gas to a user 26.

The mask shown is a nasal mask that accommodates the nasal regions ofthe user's face. It is to be understood, however, that the presentinvention also contemplates a full face or an oral/nasal mask thataccommodates both the mouth and nose of a user or a total face mask thataccommodates substantially the entire facial area of the patient. As isconventional, mask body 12 also preferably includes fastening devices,such as tabs 25 or the like, that connect to suitable adjustableretention straps (not illustrated) for retaining the mask with respectto the user's face. Although three such devices are illustrated in theFIGS. 1-4 and are generally arrayed at the corners of mask 10, it is tobe understood that other configurations, arrangements, numbers andlocations of fastening device can be provided without deviation from theprinciples of the present invention. Although not illustrated, thepresent invention contemplates providing one or more exhaust ports orother venting mechanisms at a location or locations, such as in seal 18,mask body 12, conduit 21 or at a junction between these components, toexhaust gas expired by the user to atmosphere.

Seal 18 in the illustrated embodiments includes a solid, yet highlyresilient and self-sustaining compressible, generally annular member 27comprising a peripheral wall portion 28 having a generally annular baseor inner end 30 configured so as to substantially match surface 16 ofshell 12 to which it is attached. Peripheral wall portion 28 furtherestablishes an outer end 32 generally opposite inner end 30. Outer end32 defines a generally annular contoured sealing surface 34 adapted forconfronting, sealing engagement with a user's face. As will be morefully developed later herein, in the illustrated embodiment, the contourof sealing surface 34 is preformed to closely approximate the surfacecontour of a user's facial structure, especially in the areas of thebridge of the nose, the cheeks adjacent the nose, the space intermediatethe nose and upper lip, and the intervening areas contiguous to these.It can be appreciated that a variety of different contours of sealingsurface 34 can be provided, with the user selecting the seal having acontour that most closely matches his or her facial structure, so thatthe present mask and seal offers the general macro-customized featuresdiscussed above.

It is to be understood that the contour of sealing surface 34 can havealternative configurations depending on the type of mask to which theseal is attached. For a full face mask, for example (not illustrated),sealing surface 34 is contoured to accommodate the user's chin in lieuof the area intermediate the nose and upper lip. In either case,variation in the user's facial structure, especially in the area of thebridge of the nose, for example, makes considerable seal flexibilitynecessary to accommodate the many different facial contours likely to beencountered. This is so despite that fact that a variety of differentcontours of sealing surface 34 can be provided, bearing in mind that itis only practical to provide a limited number of different contours forsealing surface 34 to facilitate the efficient mass production of seal18.

In accordance with the embodiment of the present invention illustratedin

FIGS. 3 and 4, the entirety of annular member 27 is formed from a gelsubstance, such as a viscoelastic polyurethane polymer, possessingresilience or recoil characteristics corresponding substantially tothose of human fat tissue. More specifically, seal 18 preferably has aresiliency as defined by durometer measured on the Shore 00 scale, whichis used to gauge the resiliency of very soft resilient materials, ofabout 10 or softer and, most preferably, about 0. Such resiliencycorresponds substantially to that of human fat tissue, which alsoexhibits a durometer reading of 0 on a Shore 00 scale. With respect tothe embodiment of seal 18 illustrated in FIGS. 1-4, the durometer ofseal 18 corresponds to the resultant durometers of annular member 27 andthe later described protective covering (whose durometer is essentiallynegligible because of the thinness and pliability of the covering). Asfor the seal illustrated in FIG. 5, wherein the annular member 27 has noprotective covering, the durometer of the facial seal is that of theannular member.

Although inherently capable of filling spatial voids, human fat tissuehas negligible structural integrity and may not be self-sustainingConsequently, any seal possessing structural characteristics essentiallyidentical to fat would be impractical from a usage standpoint. That is,if a seal were fabricated from a material structurally indistinguishablefrom human fat tissue in terms of resiliency, it may tend to sag into anamorphous shape under the influence of gravity and, thus, would noteffectively conform to the contours of a user's face even if theheadstrap tension was quite high. It will be appreciated, therefore,that a properly designed seal must substantially, but not identically,mimic human fat tissue from a structural, particularly resiliency,perspective. Stated differently, the seal must exhibit some measurablerecoil “memory” whereby it is structurally self-sustaining, capable ofgently conforming to the topography of a user's face under the influenceof low headstrap tensile forces, resistant to distorting gravitationaleffects and self-restorable to its original configuration when removedfrom contact with the user's face. It must also be resistant todistortion due to positive gas pressure supplied to the mask.

To simultaneously achieve these and other beneficial properties, annularmember 27 according to the present invention is preferably formed from agel substance that, while virtually indistinguishable from human fattissue when measured on the Shore 00 scale, exhibits a resiliency ordurometer on the Shore 000 scale (which scale is used to measure theresiliency of extremely soft resilient materials) of from about 20 toabout 45. By comparison, human fat tissue registers a durometer of about10 on the Shore 000 scale.

Annular member 27 is fabricated using conventional molding techniques.For example, liquid polyurethane polymer, including any plasticizers andother modifiers necessary to achieve desired finished productproperties, is poured or injected into an appropriately configured mold.The polymer is then permitted to cure, either with or without theapplication of heat depending upon the specific composition and settingcharacteristics of the polymer, until the product achieves its desiredsolid gel form.

Because the polymer of the annular member does not have sufficientstructural integrity to reliably adhere directly to the body portion 12of the mask, seal 18 also preferably comprises attachment mechanism 36that, in one embodiment of the present invention, may be integrallymolded into the inner end 30 of the annular member during its formation.Attachment mechanism 36 is desirably constructed as a substantiallyrigid annular ring having a shape corresponding to that of the inner end30 and a wall thickness less than or equal to that of the wall thicknessof the peripheral wall portion 28. At a minimum, however, attachmentmechanism 36 comprises a member less resilient than the gel substance ofthe annular member. To enhance bonding of attachment mechanism 36 to theannular member 27, the attachment mechanism desirably includes ananchorage device 38. The anchorage device, in the illustratedembodiment, comprises spaced apart formations of the attachmentmechanism defining openings or similar structures into or around whichthe fluid polymer may flow and ultimately cure during formation of theannular member. It is to be understood, however, that a variety oftechniques are contemplated from attachment mechanism 36. Any attachmenttechnique, such as screws, tacks, adhesive, or tongue and grooveassembly, can be used to secure seal 18 to mask body 12.

In the illustrated embodiment, annular member 27 includes a plurality ofintegral bosses 42 that are preferably molded into the peripheral wallportion 28 during formation of the annular member and extend from theinner end 30 toward the outer end 32. Bosses 42 provide structuralsupport to the annular member and promote uniform compression of theannular member when such member is in contact with a user's face. In oneembodiment of the present invention, the bosses are symmetricallydisposed about the peripheral wall portion and preferably correspond innumber and location to the anchorage mechanisms 38. As shown in FIG. 3,a presently preferred construction envisions five such bosses 42corresponding to five anchorage means 38. It is to be understood,however, that the number and positions of bosses 42 can be varieddepending on the desired structural characteristics to be achieved.

As previously mentioned, one embodiment of seal 18 contemplates that theannular member 27 be covered by a protective covering 40. The coveringincreases the durability of the annular member while also permittingeasy cleaning of seal 18. Covering 40 must satisfy several physicalcriteria. It must, inter alia: (1) resist tearing and puncturing, (2)tightly conform to annular member 27 without changing or deforming thecontours thereof, (3) be chemically compatible with the annual member,(4) be biocompatible and non-irritating to a user's skin, and (5) besufficiently thin and supple such that its presence has a negligibleimpact on the resultant durometer of facial seal 18. In this regard, anexemplary embodiment of the present invention contemplates that covering40 comprise a thin (approximately 2 to 10 mils thick) flexible plasticfilm. Urethane has been found to be preferable for this particularpurpose as such material meets not only the objectives of the presentinvention but is also comparatively inexpensive and easy to apply to thesurface of annular member 27.

Covering 40 may be applied to the annular member by any suitableprocess. For instance, liquid urethane may be applied by spraying ordipping and then permitted to cure. Preferably, however, the urethane isprefabricated by vacuum forming so as to produce a skin of controllableand uniform thickness that is subsequently vacuum formed to the annularmember using conventional techniques.

Once seal 18 is fully assembled, it is, in one embodiment of the presentinvention, attached to mask body 12 by coating inner end 30 of thefacial seal and/or annular seating surface 16 of the mask body 12 with asuitable adhesive and then pressing inner end 30 into abutment withseating surface 16 whereupon the adhesive is allowed to cure.

FIG. 5 illustrates a further preferred embodiment of the seal of thepresent invention, which is identified herein by reference numeral 118.Seal 118 differs from seal 18 essentially in that the annular member 27thereof has no protective covering on its outer surface. In all othermaterial respects, seal 118 is constructed and functions substantiallyidentically to seal 18.

When manufactured according to a preferred embodiment of the presentinvention, the exposed surface of annular member 27 is tacky. As such,the inherent tackiness of contoured sealing surface 34 of the annularmember may, thus, be used to the user's advantage by enhancing adhesionof the seal to the user's face. In the alternative, if tackiness is notdesired, the surface of annular member 27 of seal 118 may be coveredwith a coating of powdered talc, silicone or similar biocompatiblematerial.

As presently contemplated, the wall thickness of peripheral wall portion28 of annular seal member 27 of seals 18 and 118, excluding bosses 42,preferably ranges from about 0.2 to 0.3 inches. The weight of the seals18 and 118, depending on the size of mask bodies 12 with which they areused, ranges from about 1 to 2 ounces, a weight that has been discoveredto be virtually unnoticeable to patients who have worn masks constructedaccording to the present invention in clinical tests. Furthermore, thefat-like resiliency qualities of the gel substance that forms annularmember 27 creates in the wearer a comparatively cool and natural tactilesensation when the facial seal is in contact with the user's face. Also,much like human fat tissue performs, seals 18 and 118 effectively fillgaps and mold to the user's facial topography thereby minimizing leakageof gas supplied to the mask. Thus, seals 18 and 118 provide thebeneficial aspects of micro-customization as discussed above.

Indeed, experimental testing has shown that respiratory masks fittedwith facial seals in accordance with the present invention exhibitminimal gas leaks with headstrap tensile forces of 3 pounds or less, avalue substantially less than related masks presently known in the art.The facial seals described herein thus enable respiratory masks to beworn by users for prolonged periods with little or no measurablediscomfort. This phenomenon is especially important to users who mustwear respiratory masks for extended periods, such as patients undergoingrespiratory therapy. Such individuals find that because of the comfortafforded by the facial seals 18, 118, their compliance with therespiratory treatment increases and the therapeutic benefits of thetreatment are more fully realized.

As an alternative to the embodiments discussed above, it is alsocontemplated that a respiratory mask of the present invention may beconstructed as a one-piece member rather than as a separate seal joinedto a mask body. In such case, the respiratory mask may be fabricated asa unitary member formed from substances of increasingly softerdurometers, as considered in a direction from that portion of the maskcorresponding to the mask body toward that portion corresponding to thefacial seal, such that the softest materials, comprising the previouslydiscussed gel substance and possessing the resiliency characteristicsdescribed hereinabove, constitute the seal or face-contacting portion ofthe annular member.

As yet another alternative embodiment, the present invention alsocontemplates that annular member 27, rather than the entire mask, can bedefined by substances of increasingly softer durometers in a directiontoward sealing surface 34, such that the softest materials, comprisingthe previously discussed gel substance and possessing the resiliencycharacteristics described hereinabove, would constitute the seal orface-contacting portion of the annular member, i.e., the portions ofseal 18 at sealing surface 34.

A further embodiment of a seal of the present invention is illustratedin FIG. 6. The primary difference between the seal of this embodiment,identified by numeral 218, and seals 18 and 118 in the previousembodiments, is that seal 218 includes a first portion 50 defined by thegel substance discussed above and a second portion 52 defined by aselectively formable substance so that the general shape of seal 218 canbe customized to enable seal 218 to fit more comfortably on the patient.The remaining portions of the mask illustrated in FIG. 6 are identicalto the associated portions in the previous embodiments.

The selectively formable substance in second portion 52 of seal 218 iscapable of being placed in a malleable state so that it molds from afirst pattern into a second pattern. The formable substance is alsocapable of being placed in a fixed state so that it retains the secondpattern after being so molded. Dashed line 54 in FIG. 6 represents theinterface between first portion 50 and second portion 52 when secondportion 52 is in its original, first pattern, i.e., prior to beingmolded to match the contours of the patient. Dashed line 56, on theother hand, represents the interface between first portion 50 and secondportion 52 once second portion 52 has been molded into its secondpattern to match the contours of the patient. It can be appreciated thatsecond portion 52, in the embodiment illustrated in FIG. 6, upon beingmolded into its second pattern, has decreased the distance between innerend 30 and the interface 54, 56 between first portion 50 and secondportion 52 at the top and bottom of the seal as a result of being somolded. This may occur, for example, due to the protrusion of the bridgeof the nose and the chin.

In an exemplary embodiment of the present invention, the formablesubstance in second portion 52 of seal 218 is heat activated so that ittransitions from the fixed state to the malleable state upon beingheated to a certain level. It also transitions from the malleable stateto the fixed state upon being cooled to certain level. In one embodimentof the present invention, the formable substance defining second portion52 is a combination of the above-described gel substance and astiffening agent, such as ethyl vinyl acetate. Although a range ofmixture ratios are possible to achieve a variety of stiffnesses forsecond portion 52, in a preferred embodiment of the present invention,the second portion is a uniform mixture of approximately 60% gelsubstance and 40% stiffening agent.

This embodiment of the present invention provides a customizable sealfor interfacing an external device, such as the mask illustrated in FIG.6, with a portion of the patient, such as the area surrounding thepatient's nose or the area surrounding the nose and mouth. Morespecifically, by providing a formable substance as second portion 52 ofseal 218, the seal can be macro-customized to match the general contoursof the patient, such as the bone structure underlying the portions ofthe patient's face over which the mask is to be placed. In addition,first portion 50 of seal 218, being a gel substance as described abovewith respect to FIGS. 1-5, provides the beneficial effects ofmicro-customization in that the gel readily conforms to the externalfeatures of the patient's face and does not suffer from thedisadvantages of micro-customization because the gel need not bepatterned to match the specific features of the user. Instead, theconsistency of the gel allows the first portion to fill in the gaps onthe surface of the user once the seal is applied to the user. Thus, asingle seal 218 provides the benefits of micro-customization andmacro-customization.

Furthermore, the formable substance in second portion 52 can bereshaped, as needed, merely by causing the formable substance totransition again to the malleable state, which, in the above embodiment,is accomplished by reheating the second portion. Thus, seal 218 can bere-customized if, for example, the patient is unsatisfied with aprevious attempt to customize the seal. Still further, because the gelsubstance of first portion 50 provides the effect of micro-customizationwithout having to perform the time-consuming and typically permanentmicro-customization process discussed above and because the secondportion can be customized to match the general contours of a patient, acommonly configured seal having first and second portions 50 and 52 canbe adapted for use with a wide variety of patients, thereby maximizingthe efficiency of the manufacturing process. This feature also makes itpossible to minimize the number of different off-the-shelf variations inthe seal shape and size that must be made available in order to providea seal suitable for each patient from a group of patients having a widerange of different physical characteristics.

The process by which seal 218 is customized to match, in general, thefacial features of the patient begins with selecting a seal thatgenerally matches the user. For example, the size of seal 218 must begenerally compatible with the size of the area of the user that the sealmust cover. This is accomplished, for example, by making a variety ofsizes of seal 218 available to the user. After an appropriately sizedseal is selected, the formable portion of the seal 218 is caused totransition to a malleable state. This is accomplished, according to apreferred embodiment of the present invention, by heating at leastsecond portion 52 of seal 218 to a temperature sufficient to activatethe thermally activated material (stiffening agent) to cause it totransition to the malleable state.

Heating the second portion of the seal can be performed in a variety ofways. In a preferred embodiment of the present invention, seal 218 isplaced in a heated liquid, such as boiling water, for a period of timesufficient to cause second portion 52 to transition to the malleablestate. Typically, four (4) or more minutes is sufficient. Heating thesecond portion can also be performed, for example, by using an oven,microwaving the seal, or applying a heat source to the seal.

After the seal has been heated to a degree sufficient to cause theformable portion to transition to the malleable state, the exposedportion of seal 218, preferably the patient contacting portion 32, iscooled so that the seal can be applied to a human without substantialdiscomfort or damage to the patient's tissue. Cooling can beaccomplished, for example, by removing the seal from the heated liquidand allowing it to cool in the ambient air or in a chilled chamber, suchas a refrigerator. However, in a preferred embodiment, cooling isaccomplished by quenching, which involves placing the seal for a briefperiod of time, which is typically shorter than the period of time it isplaced in the boiling water, in a liquid, such as water, having atemperature less than that used to cause the seal to transition to themalleable state.

The relatively high thermal resistance of the seal prevents the briefcooling of its exterior, such as from quenching, from significantlyaffecting the malleability of the second portion. That is, the degree ofcooling that takes place in the cooling step should not be sufficient tocause the formable portion of the seal to transition or begin totransition to the fixed state due to the ability of the interior of theseal to retain heat and due to the relatively short quenching time.Quenching can be done to the entire seal or, preferably, quenching islimited to distal surface 32 that contacts the user. It can beappreciated that the quenching time will vary from patient to patientdepending on the patient's sensitivity to heat. It will also depend onthe location of the body where the seal is being applied, because someparts of the body are more sensitive to heat than others.

Once the exterior of the seal has been reduced to a temperature that canbe tolerated by the user, the seal is applied to the surface of the useror vice versa. This can be done by manually holding the seal against theuser or, in the case where the seal is part of a mask, by strapping themask on the user. Preferably, a sufficient force is applied on the sealso as to cause second portion 52 to take on a shape generally conformingto contours of a portion of the patient underlying the seal. As thesecond portion of the seal cools while the seal is applied to the user,the second portion transitions from the malleable state to the fixedstate, thereby retaining a shape generally conforming to the contour ofthe portion of the user underlying the seal. As noted above, dashed line56 in FIG. 6 illustrates an example of the shape of second portion 52following the above customization procedure. In this manner, theformable second portion of the seal provides a degree ofmacro-customization so that the seal conforms more closely to thegeneral contours of the user, thereby reducing pressure points andenhancing the comfort of the external device to which the seal isattached.

The above steps of causing the seal to be placed in a malleable state,placing the seal on the user to cause it to assume a patterncorresponding to the general contour of the user, and causing the sealto be placed in a fixed state after it has assumed the new pattern canbe repeated as necessary to reshape the seal. Thus, the presentinvention provides a very high degree of flexibility in matching theshape of the seal to the structure of the user. Providing a repeatablecustomization also makes it possible for the same seal to be used on avariety of patients, assuming, of course, that the appropriate cleaningand/or sterilization is done. Also, the same seal can be used on thesame patient even if the patient's general facial contours change.

In the embodiment of seal 218 illustrated in FIG. 6, first portion 50and second portion 52 are generally integral with one another with thejunction between the two portions being defined by a generally planarinterface 54. This is accomplished, for example, by providing the gelsubstance defining first portion 50 in a mold having a shapecorresponding to seal 218, and, thereafter, providing the formablesubstance defining the second portion 52 to the mold on top of the firstportion. The molding process can be performed such that two layers fusetogether or the manufacturing process can include affixing the twolayers to one another through the use of a bonding mechanism, such as anadhesive.

Although FIG. 6 illustrates a substantially planar interface betweenfirst portion 50 and second portion 52, it is to be understood, however,that the interface between first portion 50 and second portion 52 neednot be planar. On the contrary, the interface between first portion 50and second portion 52 can vary in three dimensions depending on thedesired structural characteristics of the seal. FIG. 7, for example,illustrates a seal 220 in which an interface 62 between first portion 50a and a second portion 52 a is generally planar throughout an area 64.However, at area 58, the distance from interface 62 to inner end 30decreases so that more of first portion 50 a, which contains only thegel substance, is provided next to the bridge of the nose.

FIG. 7, like FIG. 3, also illustrates a thin membrane 66 protectivecovering an exposed surface of seal 220. In FIG. 7, membrane 66 overliesboth first portion 50 a and second portion 52 a. It is to be understood,however, the membrane 66 can be provided over only one of these portionsor over selected areas of the seal depending on the characteristicdesired by the user.

Although FIG. 6 illustrates a relatively distinct separation betweenfirst portion 50 and second portion 52, it is to be understood, however,that there need not be such a distinct separation of these portions. Onthe contrary, seal 218 can be constructed and arranged so that themixture ratio of gel to stiffening agent gradually changes in thedirection from inner end 30 to outer end 32. For example, in oneembodiment of the present invention, the mixture ratio of gel tostiffening agent increases in the direction from inner end 30 to outerend 32 so that first portion 50 of seal 218, which is substantially 100%gel substance, is disposed at outer end 32, with no specifically definedtransition from second portion 52, which is proximate to inner end 30,to first portion 50.

Providing a seal in which the mixture ratio of gel to stiffening agentgradually changes in the direction from inner end 30 to outer end 32 canbe accomplished, for example, by filling a mold entirely with theformable substance, which is a combination of the above-described gelsubstance and a stiffening agent at a certain mixture ratio. Theseparate layers, or, more precisely, the change in mixture ratio frominner end 30 to outer end 32, is achieved by placing the mold on acentrifuge so that the heavier stiffening agent is drawn toward innerend 30. The change in mixture ratio in the direction from inner end 30to outer end 32 is controlled based on the time spent on the centrifugeand/or the speed of the centrifuge.

The present invention also contemplates that the mixture ratio can varyin three dimensions. For example, the mixture ratio of gel to stiffeningagent can be lower near inside surface 68 than near outer surface 70 orvice versa. Also, the rate of change in the mixture ratio from oneportion to another in seal 218 need not be constant, i.e., linear.Instead, the rate of change in mixture ratios can vary depending on thedesired characteristics for seal 218. Furthermore, the physical locationof the areas of changing mixture ratios in the seal can vary dependingon the needs of the user.

For example, second portion 50 a of the seal corresponding to the bridgeof the nose, identified as area 58 in FIG. 7, can be a mixture whose gelto stiffening agent mixture ratio is a 2:1 throughout the entire secondportion thereof, and, thereafter, changes abruptly to the first portionhaving the gel substance alone. However, in another part of the seal,such as at a portion 72 extending between the sides of the nose and thesides of the mouth, the mixture ratio of the second portion can rangefrom approximately 40% gel substance and 60% stiffening agent at innerend 30 to approximately 60% gel substance and 40% stiffening agent atthe junction between first portion 50 a and second portion 52 a, atwhich point the composition of the seal is substantially 100% gelsubstance through first portion 50 a, i.e., from interface 62 to outerend 32. In short, the present invention contemplates that the mixtureratio, the rate of change of the mixture ratio, and the location of themixture ratio can vary in three dimensions throughout the seal so longas the seal remains capable of performing the micro-customization andmacro-customization functions discussed above.

Furthermore, the present invention contemplates that there may bemultiple layers of first portion 50 and/or second portion 52 definingthe seal. For example, in an exemplary, non-illustrated embodiment ofthe present invention, a first layer of formable substance (secondportion 52) is disposed at or near inner end 30 followed by a secondlayer of gel substance (first portion 50). A third layer of formablesubstance (second portion 52) is disposed on the second layer, and afourth layer of gel substance (first portion 50) is disposed on thethird layer and defines outer end 32.

FIG. 8 illustrates another example of a seal 222 having a first portion50 b and a selectively formable second portion 52 b. In this embodiment,second portion 52 b is disposed within the gel substance of the firstportion such that the gel substance having no stiffening agent isbetween second portion 52 b and inside surface 68 and between the secondportion and outside surface 70. This embodiment simplifies themanufacturing process in that second portion 52 b is inserted into thefirst portion during the molding process, thereby eliminating thedifficult process of forming multiple layers of differing substancesadjacent one another during the manufacturing process. In addition, theshape of the insert for second portion 52 b can be easily controlled tosimplify the manner in which the shape of the formable portion, secondportion 52 b, is determined. Furthermore, providing second portion 52 bas an insert into first portion 50 b maximizes the surface area and,hence, area of contact between these two portions, thereby increasingthe bonding strength therebetween.

Referring again to FIG. 6, as with the embodiment illustrated in FIGS.1-5, an attaching mechanism 36, which, in a preferred embodiment of thepresent invention includes an anchorage device 38, attaches the seal,such as seal 218, 220 or 222, to an external member. In the illustratedembodiment, the external member is mask body 12. It is to be understood,however, that the seals of the present invention, i.e., seals 18, 118,218, 220 and 222, need not be relatively permanently affixed to theexternal member, such as the mask body. Quite the contrary, the seals ofthe present invention can be associated with the external member withoutany significant, i.e., relatively permanent, attachment between the sealand the external member. For example, FIG. 9 illustrates an embodimentof the present invention in which seal 318 is an annular member that isapplied to an exposed surface 80 of a mask 82, which is any conventionalrespiratory mask, and includes a mask body 84 and a cushion 86. Seal 318has the characteristics of any of the seals discussed above.

In one embodiment of the present invention, the exposed surface of seal318 in FIG. 9 is tacky, and the inherent tackiness of the sealfacilitates the attachment of the seal to exposed surface 80 of cushion86 and to the user. The present invention contemplates, however, that atleast a portion of seal 318 can be provided with a membrane, such asmembrane 66, or with a coating of powdered talc, silicone or similarbiocompatible material. If desired, a suitable bonding agent can beemployed to augment or provide an attaching mechanism for affixing seal318 to the mask or to the patient.

FIGS. 10 and 11 illustrate a further embodiment of a step for use in themethod by which the seal of the present invention is customized to matchthe general features of the user. In this embodiment, a retaining member80 is provided proximate to seal 218 to prevent movement of the sealduring the process in which the second portion 52 changes shape from thefirst pattern to the second pattern. Although seal 218 is illustrated inFIGS. 10 and 11, it is to be understood that the use of a retainingmember during this stage of the interfacing process is not limited tothis seal. On the contrary, retaining member 80 can be used inconjunction with any seal having a portion that is molded from a firstpattern to a second pattern, such as seal 220 or 222, to assist inretaining the shape of the seal as it is being applied to the patient tocustomize to the physical features of that patient. The presentinvention also contemplates using a retaining member in a finished sealof any of the type discussed above to augment the support of the seal inuse, i.e., to increase the stiffness of the seal.

In the embodiment illustrated in FIGS. 10 and 11, retaining member 80 isprovided proximate to seal 218 either before seal 218 is heated or aftersecond portion 52 of seal 218 has been heated to a level sufficient tocause the second portion to transition from the fixed state to themalleable state. Retaining member 80, being disposed proximate to theouter surface 70 periphery of seal 218, minimizes outward expansion ofseal 218 so that the act of compressing the seal on the user does nottend to flatten the seal, but enhances the ability of second portion 52to mold to the general shape of the patient.

It is to be understood that the retaining member can be provided at avariety of locations, or a plurality of locations, depending on how theuser wants to support the seal, either during the customization processor while the seal is in use. For example, the retaining member may beprovided proximate to the inner surface 68 and/or outer surface 70. Asillustrated by hidden line 82 in FIG. 10, which illustrates the distalsurface of retaining member 70, the retaining member can have a varietyof shapes depending on the pattern of support to be provided. It is tobe further understood that retaining member 80 need not be an annularmember, but may be a portion thereof and attachable to mask body 12, forexample, to provide the desired support function.

While the presently preferred embodiments of the seal, and, inparticular, the customizable seal, have been discussed above withrespect to its use on a respiratory facial mask as the external member,it is to be understood that there are a wide variety of alternative usesfor the seal of the present invention. For example, the presentinvention contemplates using a seal having the features described abovein conjunction with a mask that is worn to protect the user's eye, suchas goggles worn by a swimmer. The present invention also contemplatesthat the external member is an earphone or any such device thatsurrounds the user's ear. The external member can also be a headpiece orhelmet, with the seal providing a comfortable and customizable interfacebetween the user and the headpiece and/or helmet or helmet straps. Inaddition, the external member can be a garment, such as a glove or boot,with the seal being used at the cuff of the glove, for example, toprovide a seal at the user's wrist, hand or arm. The present inventionalso contemplates that the external member be a protective item, such asa shoulder pad, or a medical item, such as a cast or brace, worn by theuser. In addition, the present invention contemplates providing theseal, and, in particular, the customizable seal in conjunction withlarger external devices, such as a chair or bed, with the seal servingas a seat cushion or as an insole for a shoe, for example.

It is also not necessary for the seal of the present invention to be anannular member as generally shown in the figures. On the contrary, theseal can be formed in a variety of shapes depending on the intended use.For example, the seals of the present invention can be provided atvarious locations on a firearm, such as at the stock and/or butt, toprovide a comfortable and customizable interface with the user. In theoffice, the seal can be provided, for example, on a telephone headset, akeyboard wrist support/rest pad, a mouse, and even as a grip on awriting instrument to provide a comfortable and customizable interfacewith the user. The seal of the present invention has a wide variety ofuses in the medical devices. For example, the seal can be provided atthe earpiece of a stethoscope, in which case, it is particularlyadvantageous to provide a customizable seal so that the earpiece can betailored to fit in the ear of each individual user.

It should be further understood that the above described alternativeembodiments of the present invention are not intended to be anexhaustive list of all of the possible uses for the seal of the presentinvention. In general, the seal of the present invention can be used inany situation where there is an interface between a user and an externaldevice. It should be noted that the term “seal” is intended to encompassany interface between a patient and an external device. The term “seal”should not be construed narrowly, for example, to cover only thosesituations where the seal prevents foreign matter, such as water or gas,from passing to the user, e.g., a water-tight seal or an air-tight seal.It is not necessary in all embodiments of the present invention that theseal prevent matter from passing to the user. For example, if the sealof the present invention is used as an earpiece for a telephonereceiver, it is not necessary that the interface between the receiverand the user provided by the seal be airtight or watertight. All that isrequired is that the seal of the present invention provide a cushionedand customizable interface between the user and the external device,such as the telephone receiver.

Although the invention has been described in detail for the purpose ofillustration, it is to be understood that such detail is solely for thatpurpose and that variations can be made therein by those skilled in theart without departing from the spirit and scope of the invention exceptas it may be limited by the claims.

1. A facial seal adapted to be coupled to a mask shell, the facial sealcomprising: a mask shell attaching portion adapted to be coupled to amask shell; a patient portion adapted to contact a face of a human useror be disposed proximate to a face of a user responsive to the facialseal being donned by such a user, and wherein the patient portion isdistal from the mask shell attaching portion; and a wall portionextending between the mask shell attaching portion and the patientportion structurally supporting the patient portion relative to the maskshell attaching portion and defining a cavity adapted to receive atleast a portion of such a user's nose, wherein the mask shell attachingportion, the patient portion, and the wall portion are all part of asingle, unitary solid structure formed from a pliable viscoelasticmaterial such that the unitary solid structure exhibits viscoelasticityand recoils back to substantially its original shape when not stressed,and wherein the entirety of the mask shell attaching portion, thepatient portion, and the wall portion has a resiliency defined as aShore 00 durometer of less than about
 10. 2. The facial seal of claim 1,wherein the patient portion is provided at a first end of the wallportion and the mask shell attaching portion is provided at a second endportion of the wall portion, wherein the mask shell attaching portion isadapted to attach to a body of a respiratory mask, and wherein thepatient portion is contoured.
 3. The facial seal of claim 2, furthercomprising an attaching means for attaching the mask shell attachingportion to the body of the respiratory mask.
 4. The facial seal of claim3, wherein the attaching means comprise a member less resilient than theseal.
 5. The facial seal of claim 1, further comprising means forstrengthening the wall portion of the seal.
 6. The facial seal of claim1, wherein the seal has a generally triangular shape.
 7. The facial sealof claim 1, wherein the entirety of the mask shell attaching portion,the patient portion, and the wall portion has a Shore 000 durometer offrom about 20 to about
 45. 8. The facial seal of claim 1, wherein theviscoelastic material is a gel substance comprising a viscoelasticpolyurethane polymer.
 9. The facial seal of claim 1, further comprisinga protective covering disposed over at least a portion of the seal. 10.The facial seal of claim 1, wherein the seal is also formed from aselectively formable substance that is adapted to be molded by acompressive force acting on the patient portion from a first patterninto a second pattern and to retain the second pattern responsive tobeing so molded and even after the compressive force is removed.
 11. Arespiratory mask comprising: (a) a respiratory mask body; (b) a sealcomprising: (1) a mask shell attaching portion adapted to be coupled tothe mask body; (2) a patient portion adapted to contact a face of ahuman user or be disposed proximate to a face of a user responsive tothe facial seal being donned by such a user, and wherein the patientportion is distal from the mask shell attaching portion; and (3) a wallportion extending between the mask shell attaching portion and thepatient portion structurally supporting the patient portion relative tothe mask shell attaching portion and defining a cavity adapted toreceive at least a portion of such a user's nose, wherein the mask shellattaching portion, the patient portion, and the wall portion define aunitary structure and are all part of a single, unitary solid structureformed from a pliable viscoelastic material such that the unitary solidstructure exhibits viscoelasticity and recoils back to substantially itsoriginal shape when not stressed, and wherein the entirety of the maskshell attaching portion, the patient portion, and the wall portion has aresiliency defined as a Shore 00 durometer of less than about 10; and(c) an attaching member coupled to the mask shell attaching portion ofthe seal and to the respiratory mask body to attach the seal to therespiratory mask body.
 12. The mask of claim 11, wherein the attachingmember is less resilient than the seal.
 13. The mask of claim 11,further comprising means for strengthening the wall portion of the seal.14. The mask of claim 11, wherein the seal has a generally triangularshape.
 15. The mask of claim 11, wherein the entirety of the mask shellattaching portion, the patient portion, and the wall portion has a Shore000 durometer of from about 20 to about
 45. 16. The mask of claim 11,wherein the viscoelastic material is a gel substance comprising aviscoelastic polyurethane polymer.
 17. The mask of claim 11, furthercomprising a protective covering disposed over at least a portion of theseal.
 18. The mask of claim 11, wherein the seal is also formed from aselectively formable substance that is adapted to be molded by acompressive force acting on the patient portion from a first patterninto a second pattern and to retain the second pattern responsive tobeing so molded and even after the compressive force is removed.
 19. Afacial seal adapted to be coupled to a mask shell, the facial sealcomprising: a mask shell attaching portion adapted to be coupled to amask shell, the mask shell attaching portion having a first exteriorsurface structured to be exposed to the ambient environment surroundingthe facial seal; a patient portion adapted to contact a face of a humanuser or be disposed proximate to a face of a user responsive to thefacial seal being donned by such a user, and wherein the patient portionis distal from the mask shell attaching portion, the patient portionhaving a second exterior surface structured to be exposed to the ambientenvironment surrounding the facial seal; and a wall portion extendingbetween the mask shell attaching portion and the patient portionstructurally supporting the patient portion relative to the mask shellattaching portion and defining a cavity adapted to receive at least aportion of such a user's nose, the wall portion having a third exteriorsurface structured to be exposed to the ambient environment surroundingthe facial seal, wherein the mask shell attaching portion, the patientportion, and the wall portion, including the first exterior surface, thesecond exterior surface and the third exterior surface, are all part ofa single, unitary solid structure formed from a pliable material suchthat the unitary solid structure recoils back to substantially itsoriginal shape when not stressed and wherein the entirety of the maskshell attaching portion, the patient portion, and the wall portion,including the first exterior surface, the second exterior surface andthe third exterior surface, has a resiliency defined as a Shore 00durometer of less than about
 10. 20. The facial seal of claim 19,wherein the patient portion is provided at a first end of the wallportion and the mask shell attaching portion is provided at a second endportion of the wall portion, wherein the mask shell attaching portion isadapted to attach to a body of a respiratory mask, and wherein thepatient portion is contoured.
 21. The facial seal of claim 20, furthercomprising an attachment mechanism integrally molded into mask shellattaching portion for attaching the mask shell attaching portion to thebody of the respiratory mask, wherein the attachment mechanism is lessresilient than the mask shell attaching portion.
 22. The facial seal ofclaim 19, further comprising means for strengthening the wall portion ofthe seal.
 23. The facial seal of claim 19, wherein the seal has agenerally triangular shape.
 24. The facial seal of claim 19, wherein theentirety of the mask shell attaching portion, the patient portion, andthe wall portion, including the first exterior surface, the secondexterior surface and the third exterior surface, has a resiliencydefined as a Shore 000 durometer of from about 20 to about
 45. 25. Thefacial seal of claim 19, wherein the pliable material is a viscoelasticmaterial such that the unitary solid structure exhibits viscoelasticity.26. The facial seal of claim 25, wherein the viscoelastic material is agel substance comprising a viscoelastic polyurethane polymer.
 27. Arespiratory mask comprising: (a) a respiratory mask body; (b) a sealcomprising: (1) a mask shell attaching portion adapted to be coupled tothe mask body, the mask shell attaching portion having a first exteriorsurface structured to be exposed to the ambient environment surroundingthe facial seal; (2) a patient portion adapted to contact a face of ahuman user or be disposed proximate to a face of a user responsive tothe facial seal being donned by such a user, and wherein the patientportion is distal from the mask shell attaching portion, the patientportion having a second exterior surface structured to be exposed to theambient environment surrounding the facial seal; and (3) a wall portionextending between the mask shell attaching portion and the patientportion structurally supporting the patient portion relative to the maskshell attaching portion and defining a cavity adapted to receive atleast a portion of such a user's nose, the wall portion having a thirdexterior surface structured to be exposed to the ambient environmentsurrounding the facial seal, wherein the mask shell attaching portion,the patient portion, and the wall portion, including the first exteriorsurface, the second exterior surface and the third exterior surface, areall part of a single, unitary solid structure formed from a pliablematerial such that the unitary solid structure recoils back tosubstantially its original shape when not stressed, and wherein theentirety of the mask shell attaching portion, the patient portion, andthe wall portion, including the first exterior surface, the secondexterior surface and the third exterior surface, has a resiliencydefined as a Shore 00 durometer of less than about 10; and (c) anattaching member coupled to the mask shell attaching portion of the sealand to the respiratory mask body to attach the seal to the respiratorymask body.
 28. The mask of claim 27, wherein the attaching member isless resilient than the seal.
 29. The mask of claim 27, furthercomprising means for strengthening the wall portion of the seal.
 30. Themask of claim 27, wherein the seal has a generally triangular shape. 31.The mask of claim 27, wherein the entirety of the mask shell attachingportion, the patient portion, and the wall portion, including the firstexterior surface, the second exterior surface and the third exteriorsurface, has a resiliency defined as a Shore 000 durometer of from about20 to about
 45. 32. The mask of claim 27, wherein he pliable material isa viscoelastic material such that the unitary solid structure exhibitsviscoelasticity.
 33. The mask of claim 32, wherein the viscoelasticmaterial is a gel substance comprising a viscoelastic polyurethanepolymer.
 34. A facial seal adapted to be coupled to a mask shell, thefacial seal comprising: a mask shell attaching portion adapted to becoupled to a mask shell; a patient portion adapted to contact a face ofa human user or be disposed proximate to a face of a user responsive tothe facial seal being donned by such a user, and wherein the patientportion is distal from the mask shell attaching portion; and a wallportion extending between the mask shell attaching portion and thepatient portion structurally supporting the patient portion relative tothe mask shell attaching portion and defining a cavity adapted toreceive at least a portion of such a user's nose, wherein the mask shellattaching portion, the patient portion, and the wall portion are allpart of a single, unitary solid structure formed at least partially froma pliable viscoelastic material such that the unitary solid structureexhibits viscoelasticity and recoils back to substantially its originalshape when not stressed, wherein the entirety of the mask shellattaching portion, the patient portion, and the wall portion has aresiliency defined as a Shore 00 durometer of less than about 10, andwherein the mask shell attaching portion, the patient portion, and thewall portion include a protective covering provided on an exteriorsurface thereof having a thickness and a pliability causing theprotective covering to have a negligible durometer.
 35. The facial sealof claim 34, wherein the patient portion is provided at a first end ofthe wall portion and the mask shell attaching portion is provided at asecond end portion of the wall portion, wherein the mask shell attachingportion is adapted to attach to a body of a respiratory mask, andwherein the patient portion is contoured.
 36. The facial seal of claim35, further comprising an attachment mechanism integrally molded intomask shell attaching portion for attaching the mask shell attachingportion to the body of the respiratory mask, wherein the attachmentmechanism is less resilient than the mask shell attaching portion. 37.The facial seal of claim 34, further comprising means for strengtheningthe wall portion of the seal.
 38. The facial seal of claim 34, whereinthe seal has a generally triangular shape.
 39. The facial seal of claim34, wherein the entirety of the mask shell attaching portion, thepatient portion, and the wall portion has a resiliency defined as aShore 000 durometer of from about 20 to about
 45. 40. The facial seal ofclaim 34, wherein the viscoelastic material is a gel substancecomprising a viscoelastic polyurethane polymer.
 41. A respiratory maskcomprising: (a) a respiratory mask body; (b) a seal comprising: (1) amask shell attaching portion adapted to be coupled to the mask body; (2)a patient portion adapted to contact a face of a human user or bedisposed proximate to a face of a user responsive to the facial sealbeing donned by such a user, and wherein the patient portion is distalfrom the mask shell attaching portion; and (3) a wall portion extendingbetween the mask shell attaching portion and the patient portionstructurally supporting the patient portion relative to the mask shellattaching portion and defining a cavity adapted to receive at least aportion of such a user's nose, wherein the mask shell attaching portion,the patient portion, and the wall portion are all part of a single,unitary solid structure formed from a pliable viscoelastic material suchthat the unitary solid structure exhibits viscoelasticity and recoilsback to substantially its original shape when not stressed, wherein theentirety of the mask shell attaching portion, the patient portion, andthe wall portion has a resiliency defined as a Shore 00 durometer ofless than about 10, and wherein the mask shell attaching portion, thepatient portion, and the wall portion include a protective coveringprovided on an exterior surface thereof having a thickness and apliability causing the protective covering to have a negligibledurometer; and (c) an attaching member coupled to the mask shellattaching portion of the seal and to the respiratory mask body to attachthe seal to the respiratory mask body.
 42. The mask of claim 41, whereinthe attaching member is less resilient than the seal.
 43. The mask ofclaim 42, further comprising means for strengthening the wall portion ofthe seal.
 44. The mask of claim 41, wherein the seal has a generallytriangular shape.
 45. The mask of claim 41, wherein the entirety of themask shell attaching portion, the patient portion, and the wall portionhas a resiliency defined as a Shore 000 durometer of from about 20 toabout
 45. 46. The mask of claim 41, wherein the viscoelastic material isa gel substance comprising a viscoelastic polyurethane polymer.